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GMP AirStream 89299 Operation And Maintenance

Cable blowing machine
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All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form whatso-
ever without the written permission of General Machine Products Co., Inc.
General Machine Products Co., Inc. • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com
PNEUMATIC
Operation and Maintenance
Model 89299
CABLE BLOWING MACHINE
Page 1
Manual P/N 33709 Rev 6
040616 AKK

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Summary of Contents for GMP AirStream 89299

  • Page 1 CABLE BLOWING MACHINE PNEUMATIC Operation and Maintenance Model 89299 All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form whatso- ever without the written permission of General Machine Products Co., Inc. General Machine Products Co., Inc. • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 •...
  • Page 2 REVISION HISTORY: Rev.no Date Details Author Jul -27-10 Original issue A. Sibun AUG-26-14 Reformat for US A. Konschak April 8 15 Updated air supply quality A. Konschak Update Oiler adjustment and Oiler fill Jan 13 2016 Removed service details A Konschak Added 8.5mm March 22 Updated various photos...

  • Page 3: Table Of Contents

    CONTENTS 1. Safety Instructions 2. Critical Points that dramatically affect the operation of the machine 3. General Description 4. Specification 5. Operating procedures 6. Maintenance 7. Procedure for changing inserts in the microduct clamp 8. Procedure for changing inserts in the air box 9.

  • Page 4: Safety Instructions

    1.0 SAFETY INSTRUCTIONS THIS EQUIPMENT SHOULD BE USED ONLY BY PERSONNEL WHO HAVE BEEN GIVEN THE APPROPRIATE TRAINING, AND WHO ARE COMPETENT TO USE IT. THESE INSTRUCTIONS ARE TO BE MADE AVAILABLE TO OPERATORS OF THIS EQUIPMENT AT ALL TIMES, FAILURE TO OBSERVE THESE SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.
  • Page 5 GENERAL PNEUMATIC SAFETY INSTRUCTIONS  The GMP Fiber Optic Cable Blowing Machine is a pneumatic device, using pressurized air to project cable at high velocities. Please observe the following precautions when operating the Cable Blowing Machine:  Compressed air can cause flying debris. This could cause personal injury. Always wear personal protec- tive equipment.
  • Page 6 2.0 CRITICAL POINTS THAT DRAMATICALLY AFFECT THE OPERATION OF THE CABLE BLOWING MACHINE  PRESSURE ON THE CABLE (POSITION OF THE CLOSE ARM ASSEMBLY) SHOULD BE SET AS PER THE INSTRUCTIONS.  BELTS TO BE CLOSED AT ALL TIMES WHEN CABLE IS INSTALLED INTO MACHINE. ...
  • Page 7 DISCLAIMER General Machine Products Co., Inc. takes care in the design of its products to insure that the cable is protected during installation. Due to the variety and different methods of cable manufacture the responsibility of checking the cable compatibility with the equipment lies with the operator.

  • Page 8: General Description

    3.0 GENERAL DESCRIPTION The GMP Pneumatic AirStream machine is designed to install small diameter cable into underground microduct. The machine uses an air motor to drive a pair of compliant belts (both belts are driven). The belts are covered with a compliant coating to prevent damage to the cable. A range of different coatings and profiles are available depending on the surface texture of the cable being installed.

  • Page 9: Operating Procedures

    5.0 OPERATING PROCEDURE IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS CABLE BLOWING MACHINE:  HAVE RECEIVED COMPREHENSIVE TRAINING IN THE USE OF THIS MACHINE.  ARE COMPETENT TO USE IT,  AUTHORIZED TO USE IT AND HAVE READ AND UNDERSTOOD THIS MANUAL. ...
  • Page 10 Fit the microduct into which the cable is to be installed into the air box and mi- croduct clamp. It is recommended that a length of microduct similar in size to the microduct into which the cable is to be in- stalled be fitted in the microduct clamp.
  • Page 11 Fit the cable through the machine. Loosen the thumb Move the close assembly nut and open the to the far right to fully seal housing open the drive It is now possible to insert the cable in the machine, this can be carried out in 2 ways. Method 1: This method is only suitable if the machine has been previously set up with the correct infeed and exit guides from the belts to suit the cable being installed, see section 9 for the procedure for changing the guides.
  • Page 12 Method 2:  Move the close assembly arm fully to the right.  Remove the top halves of the belt infeed and exit guides using the knurled screws (screwdriver slots are provided if necessary). Ensure the correct guides are fitted for the cable (see appendix 1) ...
  • Page 13 Connect the air supply to the machine. The air inlet to the machine is made via a jaymac coupling on either the combined air input assembly and/or the jaymac connected to the back of the air box. An on/off valve is fitted to the air box to provide control of the air supply to the operator and a pressure gauge is fitted to indicate air box pressure.
  • Page 14 This machine operates in conjunction with the ma- chine sited at the main point of installation. The GMP Pneumatic Airstream machine is ideally suited to this type of operation, it may be coupled with a second machine to increase the distance a single cable can be installed without couplings.
  • Page 15 Note: It is only possible to reset the distance to zero if you are in ‘count’ mode. Pressing the reset but- ton while in ‘tacho’ mode will do nothing. Should it be necessary to replace the speed distance-measuring device please contact GMP. Page 15...
  • Page 16 To install cable: For the first time i.e. installing a cable type that has not been installed before and whose characteristics are unknown. Using the supplied airline adaptor, connect the air lines to the machine and the compressor (checking the ball valves and flow control valve on the motor are closed).

  • Page 17: Maintenance

    6.0 Maintenance The GMP AirStream Cable Blowing Machine has been designed to give reliable, trouble free service over long periods. The machine requires no sophisticated maintenance procedures, simple common sense checks and precautions are all that are needed. The main source of breakdown and/or malfunction of a machine being used outdoors is contamination by the elements, this contamination may be introduced into the machine in a number of different ways.
  • Page 18 Preventing as much contaminant as possible from entering the drive belt assemblies will aid the performance of the machine. If necessary remove the drive belts. (See section 12.0) and clean the assemblies. Ensure free rotation of rollers and smooth action of the Cross Arm assembly It is necessary to periodically inspect inside the base (See section 14.0 for base removal) to check for belt wear, debris and pulley wear/damage.

  • Page 19: Procedure For Changing Inserts In The Microduct Clamp

    7.0 Procedure for changing inserts in the microduct clamp  Loosen the thumb nut, rotate the swing bolt to open the microduct clamp housing  Loosen and remove the (2) m2.5 fix- ing screws. (Do not lose these screws, they will be needed for the replacement insert).

  • Page 20: Procedure For Changing Inserts In The Infeed And Exit Guides

    9.0 Procedure for changing inserts in the belt infeed and exit guides Long Insert Unscrew knurled screws secur- ing the upper guide housing If both long and short inserts are used, the long inserts are mounted in the housings at the machine inlet Loosen and remove the M2.5 screw securing the guide into the housing...

  • Page 21: Procedure For Replacing The Air Box Housing Seal

    10.0 Procedure for replacing the air box housing seal Spread adhesive along one side of cord. Apply a thin coat of 3M Rubber Cut a length of  0.08inch seal- and Gasket Adhesive to the top of ing material 2 1/8” long (a little the cut sealing material longer than is necessary).

  • Page 22: Procedure For Changing The Air Box Infeed Guide

    11.0 Procedure for changing the air box infeed guide  Loosen and remove the (2) M3 screws. (Do not mislay these screws, they will be needed for the new infeed guide.  Remove the air box infeed guide  Repeat the procedure for the infeed guide insert in the other hosing half ...
  • Page 23 loosen the tension screws remove the belt guides loosen and remove the tension nuts remove the idler pulleys and the belts Place the new belt in position on the drive pulley, place the idler pulley around the other end and replace the idler pulley onto the tensioning shaft.

  • Page 24: Procedure For Tensioning The Drive Belts

    13.0 Procedure for tensioning the drive belts Place the new belt in position in over the pulleys and ensure the belt is correctly located in all the pulley grooves. Tighten the tension screw with the tension nut slackened off slightly. This will begin to tighten the belt.

  • Page 25: Procedure For Checking And Replacing The Air Motor Drive Belt

    14.0 Procedure for checking and replacing the motor drive belt Remove the 6 screws retaining the machine base as shown below: Turn the machine over revealing the motor drive belt. Loosen the set screw retaining the idler pulley, as indi- cated below.

  • Page 26: Tensioning Of The Air Motor Drive Belt

    15.0 Tensioning of the air motor drive belt. There should be no need to alter the belt tensioning device providing it creates a deflection in the belt. However if adjustments are required of the belt tensioner it would require the removal of the air chamber as- sembly to gain access to its mounting screw through the top plate.
  • Page 27 16.0 Procedure for checking/refilling/adjusting the oil level of the air lubricator Do NOT run the machine without oil in the lubricator. Doing so will reduce machine perfor- mance while causing excessive wear and premature failure of the air motor. The machine should NOT be tipped onto its side or upside down as this will cause unwanted oil leakage into the pneumatic air lines.
  • Page 28 The amount of lubricating oil added to the air by the lubricator unit is adjustable. This is via the small knob on the top of the unit, as shown in the picture below. Lubricator Adjust Lubricator Fill The knob is labelled + and -, this will either increase or decrease the amount of oil added to the air. The opti- mum amount of added oil is three (3) drops per minute and oil is only added while the machine is in opera- tion.

  • Page 29: Monthly Service - Check List

    17.0 Monthly service – check list This section is included in the manual for your convenience, there follows a list of suggested checks, it is rec- ommended that these checks be carried out on a regular basis, depending on use. Monthly checks are con- venient;...

  • Page 30: Service History Record

    18.0 SERVICE HISTORY RECORD Carried out Service no Date Record of service/repair Page 30...

  • Page 31: Microduct Integrity And Lubrication

    19.0 Microduct integrity and Lubrication This is entirely the responsibility of the operator. To be sure that the microduct into which the cable is to be inserted is installed appropriately, it is recommend- ed that its integrity and lubrication be checked. i.e.
  • Page 32 The air box and microduct clamp are now set up to blow air through the microduct. Connect the air as for normal blowing. Make sure there are personnel at the other end of the microduct run, and that they are aware that the air is to be turned on.

  • Page 33: Recommended Spares List

    20.0 Recommended spares list 1. Microduct –‘O’ Rings – See Appendix 1 2. Cable Seal – See Appendix 1 3. Coated Cable Drive Belts – See Appendix 1 4. 2 mm cord seal – See Appendix 1 315 mA Fuses - P/N 89593 Motor Drive Belt - P/N 34742 For spare parts always quote the machine type and serial number and contact: General Machine Products Co., Inc.

  • Page 34: Troubleshooting

    21.0 Troubleshooting Drive Belts will not move; Check that the air supply is connected to both the motor circuit and airbox input. If this is the case, with the air motor ball valve and flow control valve closed, increase the pressure on the torque control.
  • Page 35 APPENDIX 1 - Cable and microduct insert selection chart This section lists the appropriate inserts collets etc required for a given cable/microduct combination. MICRODUCT COLLET AND CLAMP ASSEMBLIES 89310 MICRODUCT COLLET AND CLAMP ASSEMBLY 05mm O.D. 89311 MICRODUCT COLLET AND CLAMP ASSEMBLY 07mm O.D. 89312 MICRODUCT COLLET AND CLAMP ASSEMBLY 08mm O.D.
  • Page 36 APPENDIX 2 - Recommended torque control settings procedure This section details a procedure to assist in determining the correct torque control pressure setting when in- stalling a cable which has not been installed before, and, whose characteristics are unknown. Select a sample of the cable to be used. Pass the cable through the machine as described in the manual. Feed the cable into the beginning of a length of sample microduct (say 5 meters long).
  • Page 37 APPENDIX 3 Counter/Ratemeter Programming Instructions • Press and hold both buttons. o After 5 seconds ‘ProG’ will be displayed. Releasing the buttons will display ‘no’ • Press o ‘Yes’ is displayed • Hold and press o ‘InPol’ is displayed • Press until ‘nPn’...
  • Page 38 • Press   • Enter value 01.0  • Hold      and press        o ‘EndPro’ is displayed  • Press      un l ‘YES’ is displayed  • Hold      and press        o Programming completed  OR  • Press      un l ‘no’ is displayed  • Hold       and press        o Programming mode restarted  Page 38...
  • Page 39 Page 39...
  • Page 40 GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com Page 40...

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